Fuel Filler Flap Module With Auxiliary Breakaway Opening
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Solution Overview
Problem
The existing fuel filler flap modules in motor vehicles often face blockages, such as ice formation, which prevent the fuel filler flap from moving into the open position due to insufficient force from the motor-driven movement mechanism, necessitating a solution to overcome initial deployment resistance.
Innovation Solution
A fuel filler flap module with a mechanical deployment element, such as a torsion spring, and a motor-driven deployment means with an eccentric contour on the output shaft, providing an auxiliary force greater than the deployment force to push the flap into an initial deployment position, allowing it to overcome blockages and move into the open position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a motor-driven movement mechanism is used to pivot the fuel filler flap, then the flap can be automatically deployed, but the force is insufficient to break ice blockages
Solution Approach 1:
The deployment process is segmented into two distinct phases: an initial phase handled by the motor-driven mechanism to overcome blockages, and a subsequent phase handled by the mechanical deployment element for normal operation. This segmentation allows each component to be optimized for its specific function.
Solution Approach 2:
The motor-driven deployment means performs a preliminary action by applying auxiliary force to move the flap from the closed position to an initial deployment position, breaking any ice blockages before the mechanical deployment element takes over for the remaining movement.
2Reliability
If a stronger motor-driven mechanism is used to overcome ice blockages, then deployment reliability improves, but device complexity increases
Solution Approach 1:
The solution merges two deployment mechanisms - a motor-driven means for initial blockage overcoming and a mechanical deployment element for subsequent movement. This combination achieves reliable deployment without requiring an oversized motor, as the mechanical element provides the remaining force after initial breakthrough.
Solution Approach 2:
The motor-driven deployment means applies excessive force relative to normal operating requirements to ensure blockage overcoming, but only for the initial portion of the deployment stroke. The mechanical deployment element then provides the remaining action, allowing the motor to be smaller than it would need to be if it had to provide full deployment force.
3Stability of the object's composition
If the fuel filler flap is held in closed position due to ice formation, then sealing is maintained, but movement is blocked
Solution Approach 1:
The motor-driven deployment means applies a preliminary anti-action force in the opposite direction of the ice adhesion force, applying auxiliary force to break the ice blockage and create initial movement before the mechanical deployment element continues the opening motion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures the fuel filler flap can be reliably opened even in blocked conditions, like ice, by applying a sufficient auxiliary force to break the blockage, allowing for refueling or charging without manual de-icing, and reduces maintenance intensity with a cost-effective design.
Implementation Method 1
the mechanical deployment element is a torsion spring wound around the pivot axis
Implementation Method 2
the motor-driven deployment means has an output shaft driven by an actuator attached to the carrier, which output shaft is mounted on the carrier at a distance from the pivot axis and on which an eccentric contour is integrally formed
Data Source
AI summary
A fuel filler flap module of a motor vehicle includes a carrier, a fuel filler flap which is pivotably mounted on the carrier and is designed to be movable between a closed position and an open position, and a movement mechanism designed to move the fuel filler flap from the closed position into the open position and back into the closed position. The movement mechanism has a mechanical deployment element which is arranged on the carrier and which is designed to exert a deployment force acting into the open position on the fuel filler flap, wherein the movement mechanism has a motor-driven deployment means which is designed to push the fuel filler flap with an auxiliary force from the closed position up to an initial deployment position, which lies between the closed position and the open position, wherein the auxiliary force is greater than the deployment force.